Customer Case | NGI High-Speed, High-Current DC Power Supplies Enhance Efficient Automotive Fuse Testing

As a critical "safety sentinel" within the electrical systems of electric vehicles, fuses serve as guardians of high-voltage circuit integrity. With the ongoing surge in new energy vehicle (NEV) penetration rates in China, the rapid proliferation of high-voltage fast-charging platforms, and the increasing complexity of electronic systems within vehicles, the demand for automotive fuses is experiencing exponential growth. Third-party data indicates that the automotive fuse market in China reached a scale of 1.6 billion yuan in 2024, marking a robust year-over-year increase of 38.17%, significantly outpacing the overall growth rate of the automotive sector. This high-growth trend is anticipated to persist, with market projections estimating a breakthrough of the 2 billion yuan milestone by 2025.

Below, we present the application of NGI's high-performance, high-current DC power supplies within a leading fuse customer in the industry, identified as Customer A.

 Customer Overview

Customer A is a premier enterprise in the domestic fuse industry, specializing in the research and development, manufacturing, and sales of high-reliability intelligent circuit protection devices and fuses. The company focuses on new energy vehicles, telecommunications, rail transit, and renewable energy sectors, with products utilized by renowned companies such as Tesla, BYD, and CATL. 

Testing Requirements

The current standards for automotive fuses primarily adhere to GB/T 31465-2015 (ISO 8820:2008, MOD), with the following relevant standards:

Following initial technical consultations, it was identified that traditional testing power supplies fell short in key performance indicators such as test step editing efficiency and current rise speed.

1. Customized Test Steps:

   The majority of the customer's test subjects are various types of automotive fuses. With the swift advancement of electric vehicles, the complexity of test requirements has escalated, necessitating over 30,000 customized test steps. Traditional DC power supplies offer limited test step capabilities and complex editing processes, resulting in suboptimal testing efficiency.

2. Current Cycle Impact:

   In accordance with the road vehicle fuse testing standards GB/T31465.1 pulse requirements, after a minimum of 50,000 transient current cycles, the fuse must conform to the rated fuse time specifications outlined in the corresponding sections of the series standards. The current cycle impact test pulse is depicted in the figure below, requiring the current to swiftly attain a level of 2IR, followed by a reduction to a range between 1.25IR and 1.35IR within 0.25 seconds. During the initial 10 seconds of each cycle, the steady-state current should not dip below 0.5IR.

High Demands for Current Rise/Fall Speed and Stability

Traditional testing equipment exhibits notable deficiencies in voltage/current rise speed, typically ranging from tens to hundreds of milliseconds. In line with GB/T 31465 standards, there is a requirement for a rapid (≤10ms) DC power supply to achieve the current cycle impact pulse waveform. Furthermore, in conjunction with current cycle testing demands, the DC power supply must possess the capability for prolonged stable operation.

NGI's High-Performance Programmable Power Supplies Facilitate Efficient Fuse Testing

 To address the aforementioned testing requirements, NGI's N36200 series of wide-range programmable DC power supplies perfectly aligns with customer needs:

Comprehensive Condition Simulation

  Supports the customization of current steps, enabling rapid importation of step tables via upper computer software, facilitating efficient cycle testing of tens of thousands of custom operations, significantly enhancing testing efficiency.

High-Speed Stability

  Voltage/current rise time <10ms, with 8-hour current stability (30-minute warm-up period) maintained at <0.01%. 

Compact Design, High Current Capacity

  Ultra-compact design, featuring a 2U full width configuration of 20V/1100A/10kW, with the capability to support parallel operation of multiple units up to 11000A, optimizing customer testing space utilization.